TATA CONSULTING ENGINEERS SECTION: TITLE

TCE.M6-EL-700-001 SHEET i OF iii

SELECTION OF ELECTRICAL EQUIPMENT IN
HAZARDOUS AREAS

SELECTION OF ELECTRICAL

EQUIPMENT IN

HAZARDOUS AREAS

TATA CONSULTING ENGINEERS

414, Veer Savarkar Marg
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FLOPPY NO : TCE.M6-EL-CD-DOC-003
FILE NAME : M6-700-001.DOC

REV.NO R0 R1 ISSUE

INITIALS SIGN INITIALS SIGN INITIALS SIGN INITIALS SIGN

PPD.BY SNM Sd/- NJR Sd/-

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DATE 1993.11.22 1996.05.10

FORM NO. 020R2

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CONTENT

SR.NO. TITLE SHEET NO.

1.0 SCOPE 1
1
2.0 CODES AND STANDARDS
2
3.0 INTRODUCTION

4.0 CLASSIFICATION OF HAZARDOUS AREAS 2

5.0 FUNDAMENTALS OF IGNITION 3

6.0 PROTECTION OF ELECTRICAL EQUIPMENT FOR 6

USE IN HAZARDOUS AREAS
7.0 INTRINSICALLY SAFE CONCEPT 12

8.0 EXTENT OF LIMITS OF HAZARDOUS LOCATIONS 13

9.0 TESTING AND CERTIFYING AUTHORITIES 14

10.0 ADDITIONAL REFERENCES 14

APPENDIX-1 INDIAN/AMERICAN STANDARDS COMPARISON 16

APPENDIX-2 SUMMARY OF PROTECTION METHODS, 17

STANDARDS AND CORRESPONDING
HAZARDOUS AREAS
APPENDIX-3 FIRE HAZARD PROPERTIES OF SELECTED 18
LIQUIDS/GASES AND VOLATILE SOLIDS
APPENDIX-4 EXPLOSIVE CHARACTERISTICS OF VARIOUS 24
DUSTS
APPENDIX-5 METHODS FOR PREVENTING EXPLOSION FROM 32
ELECTRICAL ORIGINS IN HAZARDOUS
LOCATIONS

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REVISION

REV. NO. DATE DESCRIPTION

R1 96.05.02 CLAUSE 2.0, 6.0, 6.2.2, 7.3

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1.0 SCOPE

The scope of this design guide is to provide an indepth information useful for the
proper selection of electrical equipment in hazardous areas.

2.0 CODES AND STANDARDS

The following codes and standards are applicable:

IS:5571-1979 - Guide for selection of equipment for hazardous areas.

IS:5572-1994 (Part-I) – Classification of hazardous areas (other than mines) having

flammable gases and vapours for electrical installation.

IS:2148-1981 – Flameproof enclosures for electrical apparatus.

IS:7388-1974- Pressured enclosures of electrical equipment for use in hazardous

areas.

IS:6381-1972 – Construction and testing of electrical apparatus with type ‘e’

protection.

IS:4051-1967 – Code of practice for installation and maintenance of electrical

equipment in mines.

IS:3682-1966 – Flameproof alternating current motors for use in mines.

IS:8289-1976 – Specification for electrical equipment with type of protection ‘n’.

IS:8329-1976 – Classification of maximum surface temperature of electrical

equipment for use in Explosive Atmospheres.

IS:8240-1976 – Guide for electrical equipment for explosive atmospheres.

IS:8241-1976 – Method of marking for identifying electrical equipment for

explosive atmosphere.

IS:5780-1980 – Specification for intrinsically safe electrical apparatus and circuits.

IEC-79-12 – Gas and vapour group classifications

CENELEC – European Standards

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National Electric Code of USA – Articles 500, 501, 502, 503, 510, 511, 513, 514,
515, 516.

3.0 INTRODUCTION

Hazardous locations are areas in which explosive gases or vapours, combustible

dust or ignitible fibres are present or likely to be present.

The example of such areas are industries like petrochemical plants, oil refineries,
pharmaceutical plants, fertiliser plants etc. where hazardous chemicals are present
during normal/abnormal operating conditions.

4.0 CLASSIFICATION OF HAZARDOUS AREAS

IS: 5572 (part-I) – 1994 deals in detail with classification of hazardous areas, which
is as summarised below.

4.1 Zone O Areas

This is an area in which a hazardous atmosphere is continuously present. The

vapour space of a closed process vessel or storage tank is an example of this.

Since a hazardous atmosphere exists continuously, any failure of electrical

apparatus installed in Zone 0 would lead to fire or explosion, hence no electrical
equipment is permitted.

4.2 Zone 1 Areas

Any area in which a hazardous atmosphere is likely to occur under normal

operating conditions, falls under this category.

Due to presence of hazard under normal conditions, a fullest practicable application

of measures to prevent the occurrence of a hazardous electrical condition at all
times and in all circumstances is necessary.

4.3 Zone 2 Areas

An area where the explosive mixture is present, seldom in dangerous quantities. A

hazard can occur only under abnormal operating conditions.

This classification is applicable only where a fire explosion hazard is unlikely and
may be caused only by simultaneous and improbable occurrence of an arc or spark
from an electrical failure and a hazardous atmosphere arising through failure of the
conditions of control. It presupposes that any hazardous atmosphere resulting from
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an abnormal occurrence is rapidly dispersed so that its possible contact with the
electrical apparatus is of minimum duration.

4.4 Zone 3 Areas

There are the areas where hazard is not present at all and as such ordinary electrical
equipment are used. These are also called safe areas.

Indian Standard classifies hazardous areas for flammable gases and vapours only.
For combustible dust and fibre, only American National Electric codes are most
comprehensive.

Appendix-1 gives a comparative statement of Indian and American Standards.

5.0 FUNDAMENTALS OF IGNITION

In plants having hazardous environment, it is essential to know the conditions that

cause ignition which are solely attributable to electrical equipment.

The following two conditions must coexist to create an ignition:

a) The proportion of flammable substance and oxygen must permit ignition,

and the mixture must be present in sufficient quantity to provide an ignitible
atmosphere in the vicinity of electrical equipment.

b) An electric arc, a flame escaping from an ignited substance in an enclosure,

heat from electric heater etc. must be present at a temperature equal to or
greater than the ignition point of the ignitible mixture.

5.1 Properties of Ignitible Gases, Fluids, Dusts

5.1.1 Ignitible gases and fluids

In order to asses the hazard potential, it is necessary to know the following four
properties of gases/liquids:

a) Flash Point

This is the minimum temperature at which a liquid gives off sufficient

vapour to form an ignitible mixture with the air near the surface of liquid or
within the container.

Ignitible mixture is one which is within explosive range and capable of

flame propogation.
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b) Ignition Temperature

This is the minimum temperature at which the combustion can be initiated

or sustained independently of the heating or heated element.

This depends upon the following:

i) Shape and amount of space in which ignition occurs.

ii) Rate and duration of heating.

iii) Kind and temperature of ignition source.

iv) Percentage composition of gas-air mixture.

c) Flammable limits

This applies only to gases and vapours. This is a limit within which they
form flammable mixture with air or oxygen. The LEL (lower explosion
limit) is the concentration of vapour or gas in air below which flame can not
propogate. Mixture below LEL is too lean to support combustion.

The UEL is the concentration of vapour or gases in air above which flame
can not propogate.

d) Vapour density

This is the ratio of weight of volume of gas or vapour to the weight of equal
volume of dry air at NTP.

Vapour density > 1 means gas heavier than air

< 1 means gas lighter than air.

Lighter than air gases usually move upwards and disperse fast because of
low vapour density. Only in a poorly ventilated space, they produce hazard.

Hydrocarbons, which are most commonly used, have vapours heavier than
air. These disperse in all directions and are sufficient in quantity to create
hazard.

Appendix-3 gives the above properties of various chemicals used.

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5.1.2 Iqnitible dusts

At present there is no classification available for combustible dust in the Indian

Standards. IS-5571 Part-II: Combustible dust is being prepared by IS and is likely
to be available in year 1993.

As per National Electric Code (USA), combustible dusts are classified under Class
II and Class III covered in both Division I and II areas.

The following properties of combustible dust are of primary interest from an

ignition stand point:

a) Particle Size

Generally finer the dust greater is the chance of explosion. The most
explosive dust are finer than 200 mesh. Larger than 100 mesh dust is
usually not hazardous. Any dust finer than 60 mesh can be thereon into
suspension by the turbulence ahead of all explosion flame and so propogate
a dust explosion.

b) Minimum Explosive Concentration

Similar to gas and vapours, there is a minimum concentration of dust below

which an explosion will not occur.

Explosives are most violent when the concentration of dust slightly exceed
that required for stoichiometric reaction with oxygen in an atmosphere.
They are least violent at the minimum explosive concentration. Turbulence
that intimately mixes the dust and air greatly increases the violency.

Metallic dust presents a special problem because of its conductivity. It

causes tracking, shorting and arcing in ordinary electrical devices there by
creating its own source of ignition.

c) Dust layer ignition temperature

The minimum ignition temperatures of dust layers of certain dusts are

important. That of a layer of wood is 260 deg.C and that of a cloud of wood
flake is 470 Deg.C. Such a dust, if left in a layer at high temperatures, will
heat and eventually ignite. Then, the flanning layer becomes a source of
ignition for the cloud. Because of this the surface temperatures of electrical
equipment upon which dust can collect (such as motors) must be carefully
controlled.

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d) Minimum Ignition Energy

Minimum ignition energy for the spark ignition of dust cloud ranges
between 10 to 40 millijoules, about 50 times that for a flammable vapour or
gas to air mixture. These minimum ignition energies are so small that any
spark or arc from electrical equipment of higher voltage can ignite the
combustible dust.

5.2 Appendix-3 shows the properties of explosive gases, vapours, solids.

5.3 Appendix-4 shows the properties of ignitible dusts.

6.0 PROTECTION OF ELECTRIC EQUIPMENT FOR USE IN HAZARDOUS

AREAS

There are many ways in which electrical equipment can be designed or protected so
that it may be used in situations where the presence of a flammable gas could
constitute a hazard. Some methods offer a higher degree of protection than others,
but this does not necessarily imply that only techniques offering maximum
protection must be used in all circumstances.

The likelihood of a gas igniting is dependent on the probability of an explosive

mixture of gas being present at the same time as the occurrence of an electrical arc
or spark. A statistical approach to the problem would suggest that the same order of
probability of gas ignition would apply at all locations of a given plant. The level
of safety to be attained might well be influenced by the consequences of an ignition.
For example, an ignition in or near a build-up area or in an oil tanker would be
likely to be more serious that one in an automated plant and this would influence
the choice of equipment used in various parts of the plant.

The types of protection generally applicable to electric equipment for use in

hazardous areas are as follows:

Flameproof Type ‘d’

Increased Safety Type ‘e’

Non-sparking Type ‘n’

Pressurised Type ‘p’

Intrinsically safe (zone 0) ia

Intrinsically safe (zone 1) ib

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Immersed in oil o

Filed with powder q

Encapsulated m

General principles have been laid down in IS:5571-1970 for the selection of
electrical equipment in hazardous areas. In Zone 1 area flameproof or pressurised
type equipment should be used, whereas in Zone 2 area increased safety type
equipment are permitted.

6.1 Flameproof (Explosion Proof) Type ‘d’

This is defined as an enclosure for electrical apparatus that will withstand (when the
covers or other access doors are properly secured) an internal explosion of the
flammable gas or vapour which may enter or which may originate inside the
enclosure, without suffering damage and without communicating the internal
inflammation (or explosion) to the external flammable gas or vapour in which it is
designed to be used through any joint or other structural openings in the enclosures.

The essential feature of a flameproof enclosure is that the hazardous atmosphere is

not excluded from the electrical apparatus. It is recognised that an explosion may
occur inside the enclosure which the enclosure is sufficiently strong to withstand
and is so constructed that flame passing from inside to the outside is cooled to such
an extent that it is incapable of igniting the surrounding hazardous atmosphere.
This is achieved by controlling the lengths of the possible flame-paths and the
clearance in them. The joints therefore of a flameproof enclosure must normally be
metal to metal and no gasket or packing should be used between the faces of the
joints. There are, however, certain non-metallic materials, which when used in
conjunction with metal to form a joint, have been proved by tests to be capable of
forming a flameproof path, for example, certain plastic material for use as insulators
when terminal studs have to be passed through the wall of a flameproof motor.

6.1.1 Classification of gases & vapours

For the purpose of flameproof enclosure the gases and vapours have been divided
into four groups and sub-groups, the grouping being determined by the safe
maximum dimensions of the joints of enclosures for use in them. These are the gap
lengths and the flange breadth; the gap length being the distance between the two
faces of a flange and the breadth being the distance across the face of the flange.

Gas groupings are according to IS:2148-68. Group I contains one gas only –
Methane – and this group is reserved exclusively for flameproof electric apparatus
for use in coal mines. Group IIA & IIB covers the hazardous atmospheres normally
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present in the plastic, petroleum, petro-chemical industries. Sub-group IIC contains

gases and vapours for which the maximum safe gap, as at present ascertained is
considered too small to be practicable.

6.1.2 Weatherproofing of enclosure

The exclusion of the use of gaskets on the flanges of flameproof enclosure makes it
almost impossible to make a normally designed enclosure completely weatherproof.
A liberal application of grease or non-hardening compound to the flanges will give
a certain amount of weatherproofing for a limited period. Therefore an additional
protection by a canopy is recommended for motors installed in the open.

6.1.3 Cable Termination

In general, direct entry of external circuit conductors into the main enclosure is not
permitted. The flame-proof apparatus must consist of a main enclosure and one or
more terminal chambers. The cable should enter this terminal chamber through a
sealing box or through conduit or a packing gland.

Motor vibration level is likely to be particularly high in a mine and thus the danger
of premature fracture of the conduit (which is normally weak at the end of the
thread) is equally high.

For this reason conduit is always excluded for Group I motors and a sealing box
with armour clamps, almost invariably, used.

6.2 Increased Safety – Type ‘e’

6.2.1 Principle of increased safety

The increased safety concept is of German origin. This form of protection has been
applied extensively to motors and light fittings both in coal mining and
chemical/petro-chemical industries throughout Europe. The salient features are:

1. Robust enclosure – for protection against dust, moisture, corrosion and

water.

2. Extra mechanical clearance between stationary and moving parts. Facility

for measuring air gap even at site.

3. The temperature rise of the windings attained at rated output is 10 Deg. C

lower than value permitted for normal machines.

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4. Specially designed anti-loosening type terminal arrangement to withstand

temperature variations and vibrations. Special clearance and creepage
distance is maintained.

It can be defined as ‘the method of protection by which additional measures are

taken so as to give increased security to the electrical equipment against the
possibility of the excessive temperatures and of the occurrence of arcs and/or spark
during normal service life of the machine. It only applies to motors, at present, no
parts of which produce areas or sparks or exceed the limiting temperature, during
normal service.

Whereas in the case of a flameproof motor, all parts likely to ignite an explosive
mixture are enclosed in a housing which inhibits transmission of flame to the
ignitable atmospheres, the type of protection ‘e’ reduces the likelihood of ignition
thereby increasing the safety aspect by means of additional mechanical, electrical
and thermal protection methods.

In other words, sources of ignition are permissible inside a ‘d’ type enclosure,
provided the ignition is contained within the enclosure, but with in an ‘e’ type
enclosure the occurrence of the ignition is minimised from the outset.

The cost of type ‘e’ motor is substantially less than flameproof motor of equal
output rating. The other important advantage is that increased safety can be applied
to virtually any size of machine where as flameproof enclosures cease to become a
practicable proposition over 750 kW.

IEC 79-7 covers type ‘e’ enclosure, the equivalent Indian Standard being IS:6381-
1992.

6.2.2 Design Considerations

The main design features of type ‘e’ motors are:

a) The enclosure must have a high protection category to exclude dust and
water or moisture. The minimum degree of protection specified is IS 54,
according to IS:4691-1968.

b) All terminals must be designed with antiloosening devices so that

terminations stay with full pressure under conditions of specified
temperature variation and vibrations.

c) Mechanical clearance separating moving parts e.g. clearance between fan

and fan cover or the radial air gap between stator and rotor should not be

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less than specified dimensions, taking into consideration manufacturing

tolerances, eccentricities etc.

d) The insulation must meet certain specified requirements and the temperature
rise of the windings attained at rated output must be atleast 10 deg.c. lower
than the value permitted for similar insulation material in normal machines.

e) The minimum creepage distances for different grading of insulating

materials and clearances are specified.

f) All gases are classified according to their minimum ignition temperatures

into temp. class T1-T6. The limiting temperatures are specified with regard
to gas ignition and thermal stability of the material used. It is important that
the temperature of the windings and of other parts (in particular rotor of
motor) must not exceed these specified values if the motor after a prolonged
operating period remains energised in a stalled condition for a specified time
‘tE’ seconds (tE should not be less than 5 seconds).

Temperature Class Maximum surface temperature

----------------------- -------------------------------------

T1 4500C
T2 3000C
T3 2000C
T4 1350C
T5 1000C
T6 850C

6.2.3 Protection Device

The motor is required to be connected with a three-phase motor protection switch

adjusted to the rated current of the motor. When selecting the protective switch it is
important that it operates, in the event of stalling of the motor, within time ‘tE’ for
the relevant temperature class.

6.3 Non-Sparking Type ‘n’

The non-sparking type of motor is basically an Anglo-American concept which was

evolved some years ago by the oil companies and those engaged in the petro-
chemical processing industries. These were originally made to an OCMA
specification. The appropriate British Standard is BS:50000 Part 16, to which the
equivalent Indian Standard is IS:8289-1961.

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These motors are similar, in basic concept, to type ‘e’ motors, but with some
relaxation in requirements because of the lower risk in Division 2 areas to which
their application is limited.

The clauses relating to spark-free operation and mechanical clearances are similar
to type ‘e’ motors but those parts of the specifications covering terminals and their
clearances, also operating temperatures, are somewhat less stringent than for type
‘e’. The mechanical tightness of rotor bars on squirrel cage motors and general
method of construction to eliminate the risk of sparking during starting and running
is stipulated. The surface temperature of the motor is restricted to 200 Deg.C.
(assuming an ambient of 40 Deg.C). A reasonably high quality insulation system is
required on stator winding (random or “mush” windings are not permissible on 3.3
kV motors).

Attention is also paid to terminal assemblies, all h.v. cable boxes having a specified
through-fault capacity, properly short circuit tested.

Frame sizes of type ‘n’ motors are generally the same as for general purpose
motors, at least when the flammable atmosphere is limited to gases in temperature
classes T1, T2 and T3. Thus they tend to be smaller and less costly than type ‘e’
motors of equal output.

6.4 Pressurised Type ‘p’

Pressurisation is a technique whereby the dangerous parts are enclosed in a housing

which is purged with fresh air and inert gas. This ensures that explosive gas is
dispersed from within the enclosure before electrical parts are energised. The gas is
then prevented from re-entering the enclosure by maintaining its interior at a
pressure slightly above atmosphere (minimum specified is 5 mm water gauge above
atmosphere).

In the case of large electrical machines a totally enclosed dual circuit type of
enclosure is normally used such that the motor interior is pressurised with air or
nitrogen to about 75 mm water gauge above that of the atmosphere surrounding the
enclosure. The enclosure is sealed and the leakage rate controlled to about 250
litre/min. Purging inlet and outlet parts are provided and it is usual to purge with
five or six times the motor air volume.

6.4.1 Safety Device

Usually, the equipment is fitted with interlocks to ensure that, should the internal
pressure or flow rate of air or inert gas fall below a certain minimum, the supply is
cut off. The normal safety devices provided are:

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a) Pressure Measuring Device: These devices should be provided for the

operation of alarm or trip devices whenever the pressure within the casing
falls below the permitted minimum.

6.5 Appendix-2 gives the summary of protective methods, their advantages and
disadvantages.

7.0 INTRINSICALLY SAFE CONCEPT

Application and principle of intrinsic safety to electrical equipment for use in

hazardous areas represents a totally different approach than other protective
methods described earlier.

In an intrinsically safe system, safety is offered by the design of the system and not
by subsequent addition of protective measures. Safety, therefore, exists throughout
the life of equipment, during maintenance and inspite of maintenance. Whereas
safety obtained by application of say explosion proof enclosures will be readily lost
as a result of carelessness after any maintenance break.

7.1 Definition as per IS:5780

7.1.1 Intrinsically Safe Circuit

A circuit in which any spark or thermal effect produced either under normal
conditions or in specified fault conditions is incapable, in the test conditions
prescribed in this standard, of causing ignition of a prescribed gas or vapour.

7.1.2 Intrinsically Safe Apparatus

Apparatus in which all the circuits are intrinsically safe.

7.2 Grouping of Apparatus

Intrinsically safe and associated apparatus are specified in either of the following
groups:

Group I : For application in coal mining

Group II : For application in other industries

Group II is further sub-divided in group IIA, IIB or IIC according to the nature of
explosive atmosphere for which the apparatus is intended.

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7.3 Categories of Apparatus

Intrinsically safe apparatus and parts of the associated apparatus are placed in one
of the following two categories:

Category “ia”
Category “ib”

Category “ia” is incapable of causing ignition under normal operation, or with a

single fault, or with any combination of two faults, with the following safety
factors:

a) In normal operation : 1.5

b) with one fault : 1.5

c) with two faults : 1.0

Category “ib”

Apparatus of category “ib” are incapable of causing ignition under normal

condition, or with any single fault applied, with following safety factors:

a) In normal operation : 1.5

b) with one fault : 1.0 If apparatus contains no

unprotected sparking
contacts in hazardous area &
fault is self revealing

c) With two faults : 1.5

For detailed guidelines IS 5780 – 1980 shall be referred which describes in detail
the constructional requirements, test procedures, temperature classification and
components.

8.0 EXTENT OF LIMITS OF HAZARDOUS LOCATIONS

In classifying an area hazardous in a plant, it is necessary to fix the limits of

hazardous location i.e. how far above, below and outward from the source of hazard
does the hazardous location extend.

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The extent of limits of hazard is covered in detail, in ‘Guideline for Hazardous Area
Classification-R0, covered under document number M9-PCS-87 and is depicted in
sheet No. 8 to 13 of above document.

The safest electrical installation in a hazardous location, of course, is the one that
doesn’t exist. Electrical equipment, as much as possible should be situated outside
the hazardous area. It may, however, be difficult to locate all electrical equipment
outside the hazardous area.

It is necessary for the design engineer to ask the following questions:

a) Is it advisable to permit ignition within any electrical equipment in the

hazardous area?

b) Can the potential of ignition to be eliminated by removing one of the two

conditions (refer para 5.1) necessary for ignition?

The numerous options available as answers to above questions are depicted in the
diagram shown in Annexure-V.

9.0 TESTING AND CERTIFYING AUTHORITIES

In India, the Central Mining Research Station, Dhanbad carries out testing of
Flameproof Motors and there are three statutory authorities viz. Directorate Central
Mines Safety, Dhanbad. Chief Controller of Explosives, Nagpur and Directorate
General of Factory Advice Service and Labour Institute, Bombay, whose approval
is necessary for installation and operation of any electrical equipment in the
hazardous areas falling under their jurisdiction. These authorities may specify
constructional requirements for the apparatus and make regulations for its
installation and operation.

10.0 ADDITIONAL REFERENCES

a) NFPA Publication No. 497 : Classification of Class I Hazardous locations

for Electrical Installation in Chemical Plants.

b) API Publication RP500A: Recommended Practice for Classification of areas

for Electrical Installations in Petroleum Refineries.

c) Classification of Gas Utility Areas for Electrical Installations : AGA

Publication No. XF0277.

d) NFPA Publication No. 321 : Basic Classification of flammable and

combustible Liquids.
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e) NFPA Publication No. 30 : Flammable and Combustible liquid codes.

f) NFPA Publication No. 325M : Fire hazard properties of flammable liquids,

gases, volatile solids.

g) National Electric Code – USA

NFPA Publications
C/o National Fire Protection Association
470, Atlantic Avenue
Boston, MA 02210.

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APPENDIX-1

INDIAN AMERICAN STANDARDS COMPARISON

Occurrence of Hazards INDIAN STANDARDS AMERICAN CODE

CONTINUOUS ZONE 0 NOT SPECIFIED NO ELECTRICAL
HAZARD IS 5572 (PART I) EQUIPMENT
HAZARD UNDER ZONE 1 ONLY FOR DIVISION 1 FOR ELECTRICAL
NORMAL GASES & VAPOURS GASES, VAPOURS EQUIPMENT
OPERATING COMBUSTIBLE DUST
AND FIBRE
GROUP I : For Mines Class I : Gases Vapours
GROUP II
IIA) A
IIB ) REFERENCE B
IIC ) IS:2148 C
D

NOT YET FINALISED FOR COMBUSTIBLE

DUSTS CLASS II
IN DRAFT STAGE E: Metal Dust
F: Carbon; coke
G: Flouristack or grain
dust
NOT YET SPECIFIED CLASS III
Fibres – Cotton, Nylon
etc.
HAZARD UNDER ZONE 2 DIVISION 2
ABNORMAL GROUP I, IIA, IIB, IIC, CLASS I, II, III Same as
OPERATING Same as above in zone 1 in Div. 1.
CONDITIONS

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SELECTION OF ELECTRICAL EQUIPMENT IN
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APPENDIX-2

SUMMARY OF PROTECTION METHODS, STANDARDS

AND CORRESPONDING HAZARDOUS AREAS

Type of Symbol Standards Zone Advantages Disadvantages Remarks

Protection of of Haz.
Motor Area
Flameproof Ex’d’ IS:2148-1968 1.2 Robust, Permits Expensive in
IS:3682-1966 maintenance of larger sizes.
BS:4683-pt.2 internal Sometimes
VDEO170 equipment difficult to
and weather-proof.
VDEO171 Special care
IEC79-1 required in
maintenance.
Increased Ex’e’ IS:6381-1972 2 Cheaper than Required Under
Safety IEC-79-7 some careful consideration
VDEO170 alternatives, installation. for use in
and suitable for all Safety Div.1 in
VDEO171 gases. Longer dependent on India.
life than some integrity of
alternatives. manufacturer.
Non- Ex’n’ BS5000 Pt.16 2 Cheap Some designs Under
Sparking IS8289-1976 difficult to consideration
maintain for use in
Div.2 in
India.
Pressurised Ex’p’ IS:7389-1974 1,2 Very safe. Need for
IEC79-2 Equipment can auxiliary
readily be equipment to
modified and provide dry air
maintained. or inert gas.
Suitable for all
gases.

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SELECTION OF ELECTRICAL EQUIPMENT IN
HAZARDOUS AREAS

APPENDIX-3
FIRE HAZARD PROPERTIES OF SELECTED LIQUIDS, GASES, AND VOLATILE SOLIDS*

Description Flash Ignition Flammable limits Vapour Remarks

point F tempe- percent by volume density
rature F (Air-1)
Lower Upper
Isopropyl Alchohol 53 750 2.0 12 2.1
(CH3)2 CHOH
62 (2-Propenol)
Lubricating oil, Mineral 300 500
(Paraffin Oil, Motor Oil)
Methane CH4 (Marsh Gas) Gas 1004 5.0 15.0 0.6
Methyl Acetate CH3COOCH3 14 935 3.1 16 2.8
(Acid Acetic Methyl Ester)
Methyl Alcohol CH3OH 52 725 6.7 36 1.1
(Methanol)
Methyl Chloride CH3CL Gas 1170 10.7 17.4 1.8
(Chloromethane)
Methyl Ether (CH3)2O Gas 662 3.4 27.0 1.6
(Dimethyl Ether) (Methyl oxide)
Methyl Formate CH3OOCH -2 869 5.0 23.0 2.1
(Formic Acid)
2-Methyl propene CH2- Gas 869 1.8 9.6 1.9
C*CH3)CH3 (isobutylene)
NaphthaV.M. & P 50 Flash 50 450 0.9 6.7 4.1 Values may
vary
depending
on the
manufacturer
Naphthalene C1OH8 (white Tar) 174 979 0.9 6.9 4.4
Nitrobenzene C6H5NO2 *(oil of 190 900 1.8 4.3
Mirbane) @200F
Nitroethane C2H5O2 82 778 3.4 2.6
Nitroglycerine C3H5(NO3)3 518 Explodes
Nitromethane CH3NO2 95 785 7.3 2.1 May
detonate
under high
temp. and
pressure
conditions.

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SELECTION OF ELECTRICAL EQUIPMENT IN
HAZARDOUS AREAS

Description Flash Ignition Flammable limits Vapour Remarks

point F tempe- percent by volume density
rature F (Air-1)
Lower Upper
Nonane C9H2O 88 401 0.8 2.9 4.4
Octane CH3(CH2)6CH3 56 428 1.0 6.5 3.9
Paraldehyde (CH3CHO)3 96 460- 1.3 4.5
Pentane CH3(CH2)3CH3 -40 500 1.5 7.8 2.5
Petroleum Ether (Benzine) 0 550 1.1 5.9 2.5
(Naphtha, Petroleum)
Phenol C6H5OH (Carbolic acid) 175 1319 3.2
Phthalic Acid C6H4(COOH)2 334 5.73
Propane CH3CH2CH3 Gas 842 2.2 9.5 1.6
Propylene CH2COCH3 Gas 860 2.0 11.1 1.5
(Propene)
Propylene CH3 CHCH Gas 1.7 1.4
(Methylacetylene)
Styrene C6H5CH-CH2 90 914 1.1 6.1 3.6
(Phenylethylene)
Sulphur Chloride S2CL2 245 453 Decomposes
in water
Tartaric Acid (CHOHCO2H)2 410 797 1.16
Toluol C6H5CH3 40 898 1.2 7.1 3.1
(Methylbenzene) (Tolyne)
Transformer oil 295
Triethylene Glycol 350 700 0.9 9.2
Turpentine 95 488 0.8
Vinyl Acetate CH2 CHOOCCH3 18 800 2.6 13.4 3.0
Vinyl Chloride CH2CHCL Gas 882 3.6 33.0 2.2
(Chloroethylene)
Vinyl Ethyl Alcohol 200 4.7 34 2.49
CH2CH(CH2)2CH
Acetaldehyde CH3CHO (Acetic -36 347 4.0 60 1.5 Polymerizes
Aldehyde)
Acetic Acid Glacial CH3COOH 109 869 544 16.0 2.1
@212F

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SELECTION OF ELECTRICAL EQUIPMENT IN
HAZARDOUS AREAS

Description Flash Ignition Flammable limits Vapour Remarks

point F tempe- percent by volume density
rature F (Air-1)
Lower Upper
Acetone CH3COCH (Dimethyl 0 869 2.4 12.8 2
Ketone) @212F
Acetonitile CH3CH (Methyl 42 975 4.4 16.0 1.4
Cyanide)
Acetyl Chloride CH2COCL 40 734 - - 2.7
(Ethynoyl Chloride)
Acetylene CHCH (Ethine) Gas 581 2.5 100 0.9 Low
pressure
Acrolein CH2CHCHO (Acrylic -15 455 2.8 31 1.9 Unstable
Eldehyde)
Acrylonitrille 32 898 3.0 17 1.8 Polimerises
Allyiamine CH2CHCH2NH2 (2- -20 705 2.2 22 2.0
Propenylamine)
Allyl Chloride CH2CHCH2CL -25 905 2.9 11.1 2.6
(3-Chloropropene)
Ammonia, Anhydrous NH3 Gas 1204 16 25 0.6
Anyl Acetate CH3COOC5H11 77 680 1.1 7.5 4.5
(Pentanol Acetate)
Anyl Alcohol 91 572 1.2 10.0 3.0
CH3(CH2)3CH2OH @212F
(L-Pantanol)
Aniline C6H5NH2 158 1139 1.3 - 3.2
(Aminobenzene) (Phenylamine)
Benxaldehyde C6H5CHO 148 377 3.7
(Artificial Almond Oil)
Benzol C6H6 (Benzene) 12 1040 1.3 7.1 2.8
Benzol Chloride C6H5CH2CL 153 1085 1.1 4.4
(a-Chlorotoluene)
CH3CH2CH2CH3 Gas 761 1.9 8.5 2.0
CH3CHCHCH3(a-Butylene) Gas 725 1.6 10.0 1.9
CH3COOC4Hg 72 797 1.7 7.6 4.0
Betyl Alcohol 84 689 1.4 11.2 2.6
CH3(CH2)CH2OH (Butanol)
(Propylcarbinol)

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SELECTION OF ELECTRICAL EQUIPMENT IN
HAZARDOUS AREAS

Description Flash Ignition Flammable limits Vapour Remarks

point F tempe- percent by volume density
rature F (Air-1)
Lower Upper
Butylamine C4H9NH2 10 594 1.7 9.8 2.5
(1-Amino Butane)
C6H5C4H9 160 770 0.8 5.8 4.61
Chloride C4H9C 15 860 1.8 10.1 3.2
Formate HCOOC4H9 (Formic 64 612 1.7 8.2 3.5
Acid)
Acid CH3(CH2)2COOH 161 842 2.0 10.0 3.0
Carbon Desulfide CS2 -22 194 1.3 60.0 2.6
Carbon Monoxide CO Gas 1128 12.5 74 1.0
Carbobenzene C6H5CL 84 1184 1.3 7.1 3.9
(Carbobenzol) (Pheynyl
Chloride)
Chloroethanol CH2CLCH2OH 140 797 4.9 15.9 2.8
(Chloroethyl Alcohol)
Chloropropylene CH3CHCHCL 21 4.5 16 2.63
CH2C6H4OH (Cretylic Acid) 178 1110 1.4 3.7
@300F
C6H5CH(CH3)2 (Cumol) (2- 111 797 0.9 6.5 4.1
phenyl Propane)
C6H12 (hexaemethylene) -4 473 1.3 8 2.9
(CH2)3 (Trimethylene) Gas 932 2.4 10.4 1.5
CH3(CH2)8CH3 115 410 0.8 5.4 4.9
Deuterium D2 (Heavy Gas 1118 5 75
Hydrogen)
Discetone 148 1118 1.8 6.9 4.0 Ignites
CH3COCH2C(CH3)2OH spontane-
ously in
Diborane P2H6
Gas 100-125 0.8 38 1.0 moist air.
Diethyl Peroxide C2H5OOC2H5 2.3 7.7 Explodes on
heating.
Diethyl Sulfate (C2H5)2SO4 220 817 Decomposes,
(Ethyl sulfate) giving ethyl
other.
2.2-Dimethyl Propane (CH)4 Gas 842 1.4 7.5 2.5

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SELECTION OF ELECTRICAL EQUIPMENT IN
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Demethyl Sulfate (CH3)SO4 082 370 4.4

(Methyl Sulfate)
Description Flash Ignition Flammable limits Vapour Remarks
point F tempe- percent by volume density
rature F (Air-1)
Lower Upper
Thane CH3CH3 Gas 959 3.0 12.5 1.0
Ethyl Acetate CH3COOC2H5 24 800 2.2 11.0 3.0
(Acetic Ether)
Ethyl Alcohol C2H5OH 55 689 3.3 19 1.6
Ethylamine C2H5NH2 0 725 3.5 14.0 1.6 70 squeous
(Aminoethane) solution
Ethyl Bromide C2H5B -4 952 6.7 11.3 3.8
(Bromoethane)
Ethyl Chloride C2H5CL -58 966 3.8 15.4 2.2
(Chloroethane)
Ethylene H2CCH2 (Ethene) Gas 914 2.7 36.0 1.0
Ethyl Formate HCO2C2H5 -4 851 2.8 16.0 2.6
(Formic Acid) Ethyl Ester
Ethyl Mercaptan C2H5SH 80 572 2.8 18.0 2.1
(Ethanethiol)
Ethyl Nitrite C2H5OHO -31 194 3.0 50.0 2.6 Decomposes
(Nitrous Ether)
Ethyl Propyl Ether C2H5OC3H7 -4 1.7 9.0
Formaldehyde HCHO Gas 806 7.0 73 1.0
Formic Acid HCOOH 100% 156 1114 1.6
solution
Fuel oil No. 1 (Kerosene, Coal 100 410 0.7 5 Flash point
Oil) may vary.
Furan CH CHCH-CHO 32 2.3 14.3 2.3
(Furfuran)
Furfural OCH-CHCH-CHCHO 140 600 2.1 19.3 3.3
Gas, Blast Furnace 35 74
Gas, Coal Gas 5.3 32
Gas Natural 900
1170 3.8-6.5 13-17
Gas, Oil Gas 4.8 32.5
Gas,Water 7.0 72

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SELECTION OF ELECTRICAL EQUIPMENT IN
HAZARDOUS AREAS

Description Flash Ignition Flammable limits Vapour Remarks

point F tempe- percent by volume density
rature F (Air-1)
Lower Upper
Gasoline 56-60 Octane -45 536 1.4 7.6 3.4 Values may
100 Octane –36 824 1.3 7.1 vary for
different
grades of
gasoline
Heptane CH3(CH2)CH3 25 419 1.05 6.7 3.5
Haxane CH3(CH2)4CH3(Hexyl -7 437 1.1 7.5 3.0
Hydride)
Hydrazine H2NNH2 100 4.7 10.0 1.1 Ignition
temp. may
very in
contact with
iron rust,
black iron
stainless
steel, glass
Hydrocyanic Acid 96% HCN 0 1000 5.6 40.0 0.9
(Prussic Acid)
Hydrogen H2 Gas 752 4.0 75 0.1
Hydrogen Sulphide H2S Gas 700 4.0 44.0 1.2
Isobutane (CH3)3CH (2- Gas 860 1.8 8.4 2.0
Methylporpane)
Isobutyl benzene 131 806 0.8 6.0 4.6
(CH3)2CHCH2C6H5
Isoprene CH2C(CH3) CH CH2 -65 428 2.0 9 2.4

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SELECTION OF ELECTRICAL EQUIPMENT IN
HAZARDOUS AREAS

APPENDIX-4

EXPLOSIVE CHARACTERISTICS OF VARIOUS DUSTS

Type of dust Ignition Minimum Minimum Relative

temperature igniting explosive explosion
of dust cloud, energy joules concentra- hazard
C tion, as per
cu.ft.

Rauwolf is vomitoria root 400 0.045 0.055 Strong

Rice 440 0.050 0.050 Strong

Sey floor 460 0.025 0.055 Strong

Ray flour 550 0.100 0.060 Moderate

Sugar, powdered 370 0.030 0.045 Strong

Walnut shell, black 450 0.050 0.030 Strong

Wheat flour 440 0.060 0.050 Strong

Wheat, untreated 500 0.060 0.065 Strong

Wheat starch 430 0.025 0.045 Severe

Wheat straw 470 0.050 0.055 Strong

Yeast, torula 520 0.050 0.050 Strong

Arbonaceous:

Asphalt, resin, volatile content 57.5% 510 0.025 0.025 Severe

Charcoal, hardwood mix, volatile 530 0.020 0.140 Strong

content 27.1%

Coal, Colo, Brrokside, volatile content 530 0.060 0.045 Strong

38.7%

Coal, 000.,No.7, Volatile content 48.6% 600 0.50 0.040 Strong

Coal, Ky., Breek, Volatile content 40.6% 610 0.060 0.055 Strong

Coal, Pa., Pittsburgh volatile content 610 0.060 0.055 Strong

37.0%

Coal, Pa., Thick Freeport, volatile 595 0.060 0.055 Strong

current 35.0%

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SELECTION OF ELECTRICAL EQUIPMENT IN
HAZARDOUS AREAS

Type of dust Ignition Minimum Minimum Relative

temperature igniting explosive explosion
of dust cloud, energy joules concentra- hazard
C tion, as per
cu.ft.

Coal, W.Va., No.2 Gas, volatile content 600 0.060 0.060 Moderate
37.1%

Coal, Whyo., Laramie No. 3, Volatile 575 0.050 0.050 Strong

content 43.3%

Gilsonite, Utah, volatile content 86.5% 580 0.025 0.020 Severe

Lignite, Galif., volatile content 60.4% 450 0.030 0.030 Severe

Pitch, coal tar, volatile content 58.1% 710 0.020 0.036 Severe

Metals :

Aluminium 650 0.015 0.045 Severe

Antimony 420 1.920 0.420 Weak

Boron 470 0.060 0.100 Moderate

Cadmium 570 4.000

Chromium 580 0.140 0.230 Moderate

Cobalt 760 --- --- Fire

Copper 900 --- --- Fire

Iron 420 0.020 0.100 Strong

Lead 710

Magnesium 520 0.020 0.020 Severe

Molybdenum 720 --- --- Fire

Nickel 950+

Selenium 950+

Silicon 780 0.080 0.100 Severe

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SELECTION OF ELECTRICAL EQUIPMENT IN
HAZARDOUS AREAS

Type of dust Ignition Minimum Minimum Relative

temperature igniting explosive explosion
of dust cloud, energy joules concentra- hazard
C tion, as per
cu.ft.

Tantalum 630 0.220 0.200 Moderate

Tellurium 550

Thorium 270 0.005 0.075 Severe

Tin 630 0.080 0.190 Moderate

Titanium 460 0.010 0.045 Severe

Tungsten 950+

Uranium 20 0.045 0.060 Severe

Vanadium, 86 percent 500 0.060 0.220 Weak

Zinc 600 0.640 0.480 Weak

Zirconium 20 0.005 0.045 Severe

Alloys and Compounds:

Aluminium cobalt 950 0.100 0.180 Moderate

Aluminium copper 930 1.920 0.280 Weak

Aluminium iron 550 0.720 0.500 Weak

Aluminium magnesium 430 0.020 0.020 Severe

Aluminium nickel 940 0.080 0.190 Moderate

Aluminium silicon 12 percent Si 670 0.060 0.040 Strong

Calcium silicide 540 0.130 0.060 Strong

Ferrochromium, high carbon 790 --- 2.0000 -

Ferromagnese, medium carbon 450 0.080 0.130 Moderate

Ferrosilicon, 75 percent Si 860 0.400 0.420 Weak

Ferrotitanium, low-carbon 370 0.080 0.140 Strong

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SELECTION OF ELECTRICAL EQUIPMENT IN
HAZARDOUS AREAS

Type of dust Ignition Minimum Minimum Relative

temperature igniting explosive explosion
of dust cloud, energy joules concentra- hazard
C tion, as per
cu.ft.

Ferrovanddium 440 0.400 1.300 -

Thorium hydride 260 0.003 0.080 Severe

Agricultural:

Alfalfa 530 0.320 0.105 Moderate

Cereal grass 550 0.800 0.250 Weak

Cinnamon 440 0.030 0.060 Strong

Citrus peel 730 0.045 0.065 Moderate

Cocos 500 0.120 0.065 Moderate

Coffee 720 0.160 0.085 Weak

Corn 400 0.040 0.055 Strong

Corn cab 480 0.080 0.040 Strong

Corn dextrine 410 0.040 0.040 Severe

Cornstarch 390 0.030 0.040 Severe

Cotton linters 520 1.920 0.500 Moderate

Cottonseed 530 0.120 0.055 Moderate

Egg white 610 0.640 0.140 Weak

Flax shive 430 0.080 0.080 Moderate

Garlic 360 0.240 0.100 Moderate

Grain, mixed 430 0.030 0.055 Strong

Grass seed 490 0.260 0.290 Weak

Guarseed 500 0.060 0.040 Strong

Gum, Manila (copal) 360 0.030 0.030 Severe

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SELECTION OF ELECTRICAL EQUIPMENT IN
HAZARDOUS AREAS

Type of dust Ignition Minimum Minimum Relative

temperature igniting explosive explosion
of dust cloud, energy joules concentra- hazard
C tion, as per
cu.ft.

Herp hurd 440 0.035 0.040 Severe

Malt, brewere 400 0.035 0.040 Severe

Milk, slim 490 0.050 0.050 Strong

Pea flour 560 0.040 0.050 Strong

Peanut hull 460 0.050 0.045 Strong

Peat, sphagnum 460 0.050 0.045 Strong

Pecan nutshell 440 0.050 0.030 Strong

Pectin 410 0.035 0.075 Severe

Potato starch 440 0.025 0.045 Severe

Pyrethrum 460 0.080 0.100 Moderate

Titanium hydride 440 0.060 0.070 Strong

Uranium hydride 20 0.005 0.060 Severe

Zirconium hydride 350 0.060 0.085 Strong

Plastics:

Acetal resin (polyform-aldehyde) 440 0.020 0.035 Severe

Acrylic polymer resin Methyl 480 0.010 0.030 Severe

methacrylate ethyl acrylate

Alkyd resin, Alkyd molding compound 500 0.120 0.155 Severe

Allyl resin, Allyl alcohol derivative, 500 0.020 0.035 Severe

CR-39

Amino resin, Urea-formaldehyde 450 0.080 0.075 Strong

molding compound

Cellulosic fillers wood flour 430 0.020 0.035 Severe

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SELECTION OF ELECTRICAL EQUIPMENT IN
HAZARDOUS AREAS

Type of dust Ignition Minimum Minimum Relative

temperature igniting explosive explosion
of dust cloud, energy joules concentra- hazard
C tion, as per
cu.ft.

Cellulosic resin, Ethyl cellulose molding 320 0.010 0.025 Severe

compound

Chlorinated polyether resin 460 0.160 0.045 Moderate

Chlorinated polyether alcohol

Cold-molded resin 510 0.030 0.025 Severe

Petroleum resin

Coumarone-indene resin 520 0.010 0.015 Severe

Epoxy resin 530 0.020 Severe

Fluorocarbon resin 600 -- -- Fire

Fluoroethylene polymer

Furnace resin, Phenol furfural 520 0.010 0.025 Severe

Ingredients Hexamethylenetetramine 410 0.010 0.015 Severe

Miscellaneous resins 220 0.020 0.045 Severe

Petrin acrylate monomer

Natural resin Rosin, DK 390 0.010 0.015 Severe

Nylon polymer resin 500 0.020 0.030 Severe

Phenolic resin; Phenol-formaldehyde 500 0.020 0.030 Severe

moulding compound

Polycarbonate resin 710 0.020 0.025 Severe

Polyester resin; Polyethyleneterephalate 500 0.040 0.040 Strong

Polyethylene resin 410 0.010 0.020 Severe

Polyester resin; Polymethylene 520 0.640 0.115 Moderate

Polypropylene resin 420 0.030 0.020 Severe

Polyurethane resin; Polyurethane foam 510 0.020 0.025 Severe

Rayon; Rayon (viscose) flock 520 0.240 0.0558 Moderate

Rubber; Rubber, Synthetic 320 0.030 0.030 Severe

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SELECTION OF ELECTRICAL EQUIPMENT IN
HAZARDOUS AREAS

Type of dust Ignition Minimum Minimum Relative

temperature igniting explosive explosion
of dust cloud, energy joules concentra- hazard
C tion, as per
cu.ft.

Styrene polymer resin 500 0.020 0.020 Severe

Polystyrene latex

Vinyl polymer resin 300 0.010 0.020 Severe

Golyvinyl butyral

* Source: Bureau of Mines, U.S. Department of Interior

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BURNING CHARACTERISTICS OF SOME COMMON FIBRES*

Substance Specific Gravity Approximate ignition Burning

temperature, C Characteristics

Acetate 1.32 525 Melts ahead of flame

Acrilan 1.17 560 Burns readily

Arnel 1.3 525 Melts ahead of flame

Cotton 1.54 to 1.56 400 Burns rapidly

Nylon 6 1.14 530 Melts and burns

Wool 1.3 600 Melts ahead of flame

* Adapted from Wellington Sears Handbook of Industrial Textiles, Published 1963 by Wellington
Sears Co. Inc., 111 W. 40th St., New York, NY 10017

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